A piston is a component of reciprocating engines, reciprocating pumps, gas compressors and pneumatic cylinders, among other similar mechanisms. It is the moving component that is contained by a cylinder and is made gas-tight by piston rings. The piston transforms the energy of the expanding gasses into mechanical energy. The piston rides in the cylinder liner or sleeve. Pistons are commonly made of aluminum or cast iron alloys.

1. 164
International Journal of Research and Innovation (IJRI)
International Journal of Research and Innovation (IJRI)
MULTI CAVITY DIE PREPARATION, ANALYSIS AND MANUFACTURING
PROCESS OF DIESEL ENGINE PISTON
Kola Nagarjuna1
, Koyilakonda-Sumanth2
, Godi Subba Rao3
,
1 Research Scholar, Department of Mechanical Engineering, Hyderabad Institute of Technology and Management, Hyderabad, India
2 Assistant professor,Department of Mechanical Engineering, HyderabadInstitute of Technology and Management, Hyderabad, India
3 professor , Department of Mechanical Engineering, HyderabadInstituteOf Technology And Management,Hyderabad,India
*Corresponding Author:
Kola Nagarjuna
Research Scholar, Department of Mechanical Engineering,
Hyderabad Institute of Technology and Management,
Hyderabad,India
Published: July 22, 2014
Review Type: peer reviewed
Volume: II, Issue : IV
Citation: Kola Nagarjuna, Research Scholar (2015) MULTI
CAVITY DIE PREPARATION, ANALYSIS AND MANUFACTUR-
ING PROCESS OF DIESEL ENGINE PISTON
INTRODUCTION TO PISTON
In every engine, piston plays an important role in working
and producing results. Piston forms a guide and bearing
for the small end of connecting rod and also transmits
the force of explosion in the cylinder, to the crank shaft
through connecting rod.
The piston is the single, most active and very critical com-
ponent of the automotive engine. The Piston is one of the
most crucial, but very much behind-the-stage parts of
the engine which does the critical work of passing on the
energy derived from the combustion within the combus-
tion chamber to the crankshaft. Simply said, it carries
the force of explosion of the combustion process to the
crankshaft.
Apart from the critical job that it does above, there are
certain other functions that a piston invariably does -- It
forms a sort of a seal between the combustion chambers
formed within the cylinders and the crankcase. The pis-
tons do not let the high pressure mixture from the com-
bustion chambers over to the crankcase.
PISTON DESCRIPTION
Pistons move up and down in the cylinders which exerts
a force on a fluid inside the cylinder. Pistons have rings
which serve to keep the oil out of the combustion chamber
and the fuel and air out of the oil. Most pistons fitted in a
cylinder have piston rings. Usually there are two spring-
compression rings that act as a seal between the piston
and the cylinder wall, and one or more oil control ring s
below the compression rings. The head of the piston can
be flat, bulged or otherwise shaped. Pistons can be forged
or cast. The shape of the piston is normally rounded but
can be different. A special type of cast piston is the hyper-
eutectic piston. The piston is an important component of
a piston engine and of hydraulic pneumatic systems. Pis-
ton heads form one wall of an expansion chamber inside
the cylinder. The opposite wall, called the cylinder head,
contains inlet and exhaust valves for gases. As the piston
moves inside the cylinder, it transforms the energy from
the expansion of a burning gas usually a mixture of petrol
or diesel and air into mechanical power in the form of a
reciprocating linear motion. From there the power is con-
veyed through a connecting rod to a crankshaft, which
transforms it into a rotary motion, which usually
Abstract
A piston is a component of reciprocating engines, reciprocating pumps, gas compressors and pneumatic cylinders,
among other similar mechanisms. It is the moving component that is contained by a cylinder and is made gas-tight by
piston rings. The piston transforms the energy of the expanding gasses into mechanical energy. The piston rides in the
cylinder liner or sleeve. Pistons are commonly made of aluminum or cast iron alloys.
In our project a piston for 1300cc diesel engine car will be designed using empirical formulas for the material Cast
Iron. A 2D drawing is created from the calculations. The piston is modeled from 2D drawing using CREO parametric
(Pro/Engineer) software.
Validation of die will be done using structural and dynamic analysis done in Ansys.
Generally manufacturing process for pistons is casting. So we have to design a die tool for the piston manufactur-
ing. Designing of casting tool die for four cavities will be done. Core and Cavity will be extracted and total die will be
designed as per the standards. CNC program will be generated for both core and cavity.
Modeling, core – cavity extraction, die design and CNC program generation is done in CREO parametric (Pro/Engineer)
software.
1401-1402

2. 165
International Journal of Research and Innovation (IJRI)
Drives a gearbox through a clutch. Components of a typi-
cal, four stroke cycle, DOHC piston engine. (E) Exhaust
camshaft, (I) Intake camshaft, (S) Spark plug, (V) Valves,
(P) Piston, (R) Connecting rod, (C) Crankshaft, (W) Water
jacket for coolant flow.
Suzuki GS 150 R specifications
Engine type : air cooled 4-stroke SOHC
Bore ×stroke(mm)=57×58.6
Displacement =149.5CC
Maximum power = 13.8bhp @8500rpm
Maximum torque = 13.4Nm @ 6000 rpm
Compression ratio =9.35/1
3D MODEL PREPARATION
SKETCHER
REVELOVED MODEL
SLOT CUTTING
INTRODUCTION TO CASTING
Casting is one of the oldest procedures done on metals.
Many products are formed using this method. Here is an
attempt to share the knowledge of casting.
Casting is one of four types: sand casting, permanent
mold casting, plaster casting and Die casting. All these
types of castings have their own advantages and disad-
vantages. Depending on the properties of the product re-
quited, one of the casting is selected.
Sand Casting: Sand casting is the oldest casting of the
above. This method of casting is in use since 1950.The
texture of the product depends on the sand used for cast-
ing. The end product is given smooth finishing at the end.
Usually iron, steel, bronze, brass, aluminium, magnesi-
um alloys which often include lead, tin, and zinc are used.
DIE CASTING
Die casting is a metal casting process that is character-
ized by forcing molten metal under high pressure into a
mold cavity, which is machined into two hardened tool
steel dies. Most die castings are made from non-ferrous
metals, specifically zinc, copper, aluminium, magnesium,
lead, pewter and tin based alloys. Depending on the type
of metal being cast, a hot- or cold-chamber machine is
used.
Volume of the component ;(v) =83406.96
Projected area ;(a)=3569.66
A1 (side wall) =1275.88
Density of material ;26e-6+
Mass No Of Cavities x=4
Total projected area =a*x
=3569.66*4
A=14278.64
Projected area of over flows and feed system
Af=A *c/100
C=10% of A
=142.78
Over all projected area:-
=A+a1+Af
=14278.64+142.78+1275.88
=15697.3mm2
Specific injection pressure of aluminum for
pressure DIA casting =8kgf/mm2
Total force acting on die plates
F=projected area *injection pressure
=15697.3*8
=125578.4kg
=125.57 Tons
Considering factor of safety of *1.2
125.5784*1.2=150.69=151 Tons
Required clamping force >150 tons
160 tons machine specifications
Clamping force =160 tons
Die stroke =380mm
Die - height =200-550mm
Plate size =675*680
Injection stroke (L)=340
Plunger die =50,60,65mm
Shot wt =1.3,1.8,2.1
FILL TIME :- 0.092(582-516+(0.3*4.8))8.93/(516-100)
=0.092(66+(1.44))8.923/416
=0.092*67.44*8.93/416
=55.40/416
=0.133sec
=133 kg sec
MANUFACTURING (MOLD EXTRACTION)
A die is usually made in two halves and when closed
it forms a cavity similar to the casting desired. One half of
the die that remains stationary is known as cover die and
the other movable half is called “ejector die”.

3. 166
International Journal of Research and Innovation (IJRI)
Molds separate into at least two halves (called the core
and the cavity) to permit the part to be extracted. In gen-
eral the shape of a part must not cause it to be locked into
the mold. For example, sides of objects typically cannot be
parallel with the direction of draw (the direction in which
the core and cavity separate from each other). They are
angled slightly (draft), and examination of most plastic
household objects will reveal this. Parts that are "bucket-
like" tend to shrink onto the core while cooling, and after
the cavity is pulled away. Pins are the most popular meth-
od of removal from the core, but air ejection, and strip-
per plates can also be used depending on the application.
Most ejection plates are found on the moving half of the
tool, but they can be placed on the fixed half.
Core: The core which is the male portion of the mold forms
the internal shape of the molding.
Cavity: The cavity which is the female portion of the mold,
gives the molding its external form.
Shrinkage allowance considered as 1.3% for aluminum
and the mould draft considered as 1°.
CORE & CAVITY PREPARATION OF MODEL
PARTING SURFACE
CAVITY
CORE
CASTING TOOL DESIGN FOR MULTY CAVITY PISTON
EXPLODED VIEW
STRUCTURAL ANALYSIS ON MULTI CAVITY PISTON
DIE
The above image shows imported model
The above image shows meshed model

4. 167
International Journal of Research and Innovation (IJRI)
The above image shows load applied
The above image shows total deformation
The above image shows stress
INTRODUCTION TO MANUFACTURING
The manufacturing of various products is done at differ-
ent scales ranging from humble domestic production of
say candlesticks to the manufacturing of huge machines
including ships, aeroplanes and so forth. The word manu-
facturing technology is mainly used for the latter range of
the spectrum of manufacturing, and refers to the com-
mercial industrial production of goods for sale and con-
sumption with the help of gadgets and advanced machine
tools. Industrial production lines involve changing the
shape, form and/or composition of the initial products
known as raw materials into products fit for final use
known as finished products.
PROCEDURE OF MANUFACTURING
CAVITY ROUGHING
CUTTING TOOL
VERICUT
ROUGHING PROGRAM
%
G71
O0001
(D:nsrroughing.ncl.1)
N0010T1M06
S5000M03
G00X5.Y-5.
G43Z0.H01
G01Z-5.F200.
X201.177
Y-9.914
X5.
Y-14.828
X201.177

5. 168
International Journal of Research and Innovation (IJRI)
Y-19.742
X5.
Y-24.656
X201.177
Y-29.57
X5.
Y-34.484
X201.177
Y-39.398
X5.
Y-44.313
Results table
STRUCTURAL ANALYSIS
Existing Model Modified Model
Total deformation 0.010822 0.0090683
Stress 37.317 31.116
Strain 0.00034214 0.00028758
FATIGUE ANALYSIS
Existing Model Modified Model
LIFE 1e6 1e6
Damage 1000 1000
Safety factor 2.3099 2.7703
Biaxiality indica-
tion
0.98181 0.99333
Alternating stress 37.317 31.116
graphs
Conclusion:
This project work deals with “Multy cavity die preparation
and manufacturing process of diesel engine piston".
In the first step data collection and inputs are collected
for the design of piston for diesel engine.
In the next step design calculations are done using math-
ematical formulae’s from the calculations piston dimen-
sions are required.
A 3d model was generated using above calculations.
Tool design calculations are done to prepare the die as-
sembly.
Core and cavity inserts are prepared using manufactur-
ing model in pro- engineer.
Mould tool parts are prepared and assembled withdrew
set.
Structural and Fatigue Analysis is conducted on mold to
find structural and Fatigue behavior to, modification’s
done for core & cavity models to increase strength by add-
ing stress relief holes.
CNC program was generated for both core and cavity in-
serts.

6. 169
International Journal of Research and Innovation (IJRI)
By observing above information it concludes that using
above process piston manufacturing can be done with
multy cavities so it increases the production rate which
in terms effect’s on reduction of cost of part production.
REFERENCES
1.Thermal analysis and optimization of i.C. Engine piston
using finite element method
2.Design and analysis of i.C. Engine piston and piston-
ring using catia and ansys software
3.Design analysis and optimization of piston using catia
and ansys
4.Simulation of thermal-mechanical strength for marine
engine piston using fea
5.Thermal analysis and optimization of i.C. Engine piston
using finite element method
6.Modeling and analysis of diesel engine piston
7.Modeling, analysis and optimization of diesel engine
piston
8.Thermal analysis of diesel engine piston
9.Finite element analysis and optimization of i.C. Engine
piston using radioss and optistruct
author
Kola Nagarjuna
Research Scholar,
Department of Mechanical Engineering,
Hyderabad Institute of Technology and Management,
Hyderabad,India
Koyilakonda-Sumanth
Assistant professor
Department of Mechanical Engineering,
Hyderabad Institute of Technology and Management,
Hyderabad,India
Godi Subba Rao
professor
Department of Mechanical Engineering,
Hyderabad Institute of Technology and Management,
Hyderabad,India